After spending time my diagnosing my noisy belt I noticed that not only is the tensioner out of alignment it is rubbing against the pulley in front of it. I pulled it out and it had separated so that the front section was out a good 6-8mm. After pressing it back together it appears that this is held together only as a press fit. That seems pretty lame. I ground down a washer small enough to fit in the recess but big enough to meet the shoulder on the cast section. It tracks beautifully and the little tractor is back to being quiet or at least quieter. Looking at it I am wondering if the system may compromise the "springyness" of the assembly and will have to see if the belt stays sane over the next week or two.

I think that this assembly is a pretty weak design, it should have some form of mechanical limit to keep the assembly together. I really don't want to shell out $180 for a new one which seems like robbery but that is because I am cheap.

Clay in SLC

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2005 Sport CRD
GDE Eco Tune
245/75 on Moabs
Magnaflow (ish) exhaust

Interesting, pictures/drawing/size of washer? I know this may sound odd but I done similar things; would some locktite red help the "glue" the press fit together?

FYI one reason for serp belt tensioner failure is a bad clutched pulley most commonly the alternator but it could include AC or viscous heater. Pop the engine cover, crank the engine, at idle look down the serp belt to the tensioner; if it's running essentially in one position all is well but if it has any noticable bounce something is wrong.

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Sold to LOST member my 05 Ltd, GDE Stg II turbo + TCM tune, SunCoast TC w. Transgo kit, Steiger window regulators, Samcos, Fumoto valve, 2nd gen filter head with Lub. Spec. bleeder, Hayden clutch & 11 blade fan, inverted spare, P-1 battery, BF Goodrich Long Trail TAs, Etecno1 glow plugs, timing belt at 50K miles/8 yrs

Yep this all started with a bad Alt clutch so I have that covered. I didnt take a picture but basically the recess where the bolt fits is larger then the press fit portion. To get it back together I used a pair of big pipe wrenches to line it back up and then persuaded it with a brass hammer. It went back together fairly easy so I didn't have faith it would stay.

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2005 Sport CRD
GDE Eco Tune
245/75 on Moabs
Magnaflow (ish) exhaust